POSIPUCKS is our unscrambler for plastic bottles that uses pucks to hold and transport any type of bottle on filling lines, especially in the cosmetic industry. No matter the shape of the container, the speed of the line or if the line is multi-format, our automatic unscrambler for containers within pucks meets any challenge and offers maximum efficiency and flexibility.
POSIPUCKS is a pioneering unscrambler developed by Posimat more than 30 years ago. The objective was to respond to the challenges of the bottling industry, especially the cosmetic and personal care sector, where they began to develop containers with irregular and more original shapes, and that presented little stability to be transported by the bottling line. For this reason, the cosmetic packaging sector began to work with those 'cups' called pucks.
The concept is simple, but extremely efficient: at the beginning of the line, the bottles are inserted into the cavities within the pucks. They are transported down the line and are not removed until they are filled, capped, and labeled, that is, at the end of the line.
An important factor to consider in this process is the speed of the line. If the line works at low speed, the operation of inserting and removing bottles from the pucks can be carried out manually (if labor costs allow it). However, the market has evolved and, with it, the requirements of the industry. Currently, higher line speeds are demanded, which does not allow the line to be fed manually. And, given the current health situation, even on low-speed lines, it is necessary to automate all operations since less manual handling of the containers and greater distance between operators is required.
For this reason, today it is so necessary to contemplate the automation of the feeding of bottles in pucks for the filling line and to know all the advantages that our Posipuck automatic unscrambler offers.
Packaging quality
Another advantage of using the puck system is that the contact of the container with the equipment on the line is minimized. Thus, the bottles travel through the filling line without being in contact with fixed elements such as guides or stars on the filling line, so that the delicate surface of the container is protected and its label is protected. This is an important point to assess when it comes to high-end packaging in the cosmetic sector.
Format change for multiple bottles
Working with pucks on a filling line also has the advantage of eliminating the time of a change of format on the entire bottling line. The fact that the bottles are inside the pucks, whose external measurements are constant for the same bottling line, allows that the machines on the filling line do not have to change parts for a format change, which means saving time spent on changing augers, stars, conveyor guides, etc. The only equipment that will need format change parts is the bottle feeder or unscrambler for each time a bottle is changed.
This is one of the great differentiating and competitive advantages of the POSIPUCKS bottle unscrambler, which makes it perfect for industries such as cosmetics, where bottle type changes are usually very frequent.
By having the same patented format change systems as the rest of POSIMAT unscramblers, it is a simple and fast operation; a task that can be carried out by any unskilled operator since it only requires changing format pieces, plug and play, without the need to use any tools.
Likewise, POSIPUCKS also offers the option of automatic and instant format change thanks to our POSIFLEX system, without the need to use any format change parts for the unscrambler.
Both systems (manual and automatic) allow for adding different bottles in the future.
Key benefits of POSIPUCK
As in any POSIMAT unscrambler, efficiency is another of the great values of POSIPUCKS. The current POSIPUCKS system guarantees that 100% of the pucks that come out of the unscrambler reach the filler with a bottle inside without having to use an empty puck recirculation system, which takes up space and increases the total cost of the project.
Insisting on the concept of efficiency, another of POSIPUCK's values is that it has the “open funnels” system, according to which any bottle misplaced in the funnel or any foreign element that enters the machine is expelled to the outside avoiding stoppages on the line. Likewise, if bottles with a larger diameter than expected are put in by mistake, the system automatically rejects it since it will not be able to be placed correctly into the puck.
Likewise, orientation systems can be adapted to rotate the puck so that any combination of asymmetric bottle - asymmetric puck is unscrambled and reaches the filler correctly.
In short, thanks to our POSIPUCK system you will achieve greater control and stability of the containers along the line, as well as a greater OEE (overall effective efficiency) by registering fewer stops due to failures and fewer changes of format.
Depending on the needs of each project and sector, the design of the line or the different machines involved in the process, different types of pucks are used.
At POSIMAT we adapt our unscramblers to the client's puck. Each project requires a particular puck design and at POSIMAT we know the challenges that each design entails:
- Loose
 |
 |
- Tight.
The inner part has less space than in the previous type, so the bottle must be inserted with some pressure, so that it remains fixed. It is the most appropriate type of puck when one of the machines in the line needs greater precision and therefore the bottles must be perfectly secured inside the puck.
 |
 |
- Labeling.
The bottle is held inside the puck only by its narrow sides, leaving practically the entire front and back surface free and thus being able to apply the label. This is the puck that presents the greatest challenges for the feeding system since the bottle must be inserted with great precision; precision that cannot be lost when transporting the puck to the filler. Obviously, the higher the speed of the fill line, the greater the challenge.
 |
 |
POSIPUCKS success stories
The first POSIPUCK was manufactured for the American company Cosmair, of the L'Oréal Group, in 1994. Since then, at Posimat we have manufactured hundreds of units of these unscramblers throughout the world.
A recent example of the application of POSIPUCK was the adaptation of our system to a line with different formats, where only one of them was transported with pucks. Faced with this challenge, we designed and manufactured an adaptation of our POSIFLEX automatic change unscrambler system with a BTU-type puck inserter and orienting equipment. The goal was for only this bottle to go through the BTU and the rest to go straight to the fill line.
Thanks to this transport system, the equipment was able to work with bottles with and without a puck, guaranteeing the stability of the containers throughout the process when unscrambling and transporting them in the most efficient way.
Due to our experience in the sector and our constant commitment to innovation, at POSIMAT we have the ability to adapt our technology to any project. We have a wide portfolio of technical solutions to customize our standard unscrambler with any type of puck and container, responding to all kinds of challenges, regardless of the level of complexity of the proposed project.
AT POSIMAT WE GUARANTEE THE BEST SERVICE DURING THE WHOLE LIFE CYCLE OF THE EQUIPMENT.
TO DO THIS, WE HAVE WORLDWIDE TECHNICAL ASSISTANCE THANKS TO OUR NETWORK OF HIGHLY QUALIFIED OWN AND LOCAL EXPERTS. CONTACT US!